A Method of filtering a fluid with a filter assembly

ABSTRACT

A filter assembly and a method of filtering a fluid using the filter assembly are disclosed. The filter assembly includes wave coils arranged axially to define a filter element. The filter element includes bottom and top ends and an inner cavity. The filter assembly also includes a base plate that engages one, or both, ends to support the wave coils. The fluid flows toward the base plate, and the base plate diverts the fluid inside or outside the inner cavity. The wave coils include crests and troughs. engaging one another on adjacent wave coils to define filtration apertures. The diverted fluid is filtered through the filtration apertures such that a filtrate of the fluid passes through the inside or outside of the inner cavity, and a retentate of the fluid is retained on the other of the inside or outside of the inner cavity relative to the filtrate.

RELATED APPLICATIONS

The present application claims priority to and all advantages of U.S.Provisional Patent Application No. 60/225,895, which was filed on Aug.17, 2000.

BACKGROUND OF THE INVENTION

1). Field of the Invention

The subject invention generally relates to a filter assembly and methodof filtering utilizing the filter assembly to filter a fluid. Morespecifically, the subject invention relates to an adjustable filterassembly including a filter element and filtration apertures that aredefined between crests and troughs of adjacent wave coils of the filterelement wherein the filtration apertures are adjustable.

2). Description of Related Art

Spring filters are known in the art. Helically- or spirally-wound springfilters are also known in the art. Examples of such conventional springfilters are disclosed in U.S. Pat. Nos. 4,113,000; 4,199,454; and5,152,892. Conventional spring filters, including the helically- andspirally-wound spring filters disclosed in the above-referenced patents,are deficient for various reasons. For instance, certain conventionalspring filters are not adjustable. Other conventional spring filters arenot easily adjustable and are not easily manufactured. As one specificexample, the conventional spring filter disclosed in the '892 patent isdeficient because the entire coil of this conventional spring filter,which is made up of a plurality of individual flat coils, is extremelyweak having a k factor of about zero. As a result, filtration gaps, orfiltration apertures, can not be maintained between the individual flatcoils when the spring filter is vertically-oriented. This conventionalspring filter is also particularly difficult to manufacture. Morespecifically, this conventional spring filter requires that theindividual flat coils of the filter be manufactured such that thefiltration apertures, between adjacent flat coils progressively increasein size and pitch which, as understood by those skilled in the art, is aparticularly cumbersome requirement. This conventional spring filterfurther requires that projections be machined into each coil to maintaina minimum filtration aperture between adjacent coils of the filter, thusinvolving additional machining requirements and even limits on size ofthe spring filter.

Due to the deficiencies identified in the spring filters of the priorart, including those set forth above, it is desirable to implement anadjustable filter assembly that is ideal to manufacture and thatuniquely defines a filtration aperture between adjacent coils of afilter element for optimum filtering of fluids due to the adjustabilityof the filtration aperture. It is also desirable that the adjustablefilter assembly according to the subject invention can be easilymanufactured into a wide range of sizes and stiffnesses of the filterelement.

SUMMARY OF THE INVENTION AND ADVANTAGES

A filter assembly and method of filtering utilizing the filter assemblyto filter a fluid are disclosed. The filter assembly includes aplurality of wave coils. The wave coils include at least one crest andat least one trough and are arranged axially to define a filter element.The filter element includes first and second ends and an inner cavity.The filter assembly also includes a support that engages either thefirst or second end of the filter element for supporting the wave coils.The support also diverts the fluid inside or outside of the inner cavityof the filter element. The crest of one wave coil engages the trough ofan adjacent wave coil to define at least one filtration aperture betweeneach crest and each trough of the adjacent wave coils.

The fluid flows toward the support such that the support diverts thefluid to the inside or the outside of the inner cavity of the filterelement. The fluid diverted by the support is filtered through thefiltration apertures. More specifically, if the fluid flows toward thesupport and is diverted to the inside of the inner cavity and thenthrough the filtration apertures, then a filtrate of the fluid, whichalso flows through the filtration apertures, passes through the outsideof the inner cavity, and a retentate of the fluid, which cannot flowthrough the filtration apertures, is retained on the inside of the innercavity of the filter element. Alternatively, if the fluid flows towardthe support and is diverted to the outside of the inner cavity and thenthrough the filtration apertures, then the filtrate of the fluid. flowsthrough the filtration apertures and passes through the inside of theinner cavity, whereas the retentate of the fluid is retained on theoutside of the inner cavity of the filter element.

Accordingly, the subject invention provides a filter assembly thatestablishes a filtration aperture between adjacent coils of a filterelement included in the filter assembly. Additionally, the filterassembly of the subject invention is easily manufactured.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1A is a side view of a filter assembly illustrating a plurality offiltration apertures defined between crests and troughs of adjacent wavecoils of a filter element of the assembly;

FIG. 1B is a perspective view of the filter element of the assemblyillustrating the plurality of wave coils arranged axially and definingan inner cavity;

FIG. 2A is an enlarged side view of a portion of the filter element;

FIG. 2B is an enlarged side view of a wave coil having crests andtroughs;

FIGS. 3A through 3C are side views of various shearing surfaces of wavecoils including a plurality of ridges for enhancing shear forcesimparted on a fluid that is to be filtered

FIG. 4 is an exploded perspective view of the filter assembly incombination with a canister for filtering the fluid;

FIG. 5A is a partially cross-sectional side view of the filter assemblyillustrating an inlet valve disposed at an inlet of the filter canisterand an outlet valve disposed at an outlet of the filter canister;

FIG. 5B is a schematic representation of a backwash position of theinlet valve at the inlet of the filter canister;

FIG. 6A is a partially cross-sectional side view of the filter assemblydisposed in the filter canister illustrating an alternative adjustmentmechanism including a manual adjustment assembly for modifying a lengthL of the filter element to reduce and expand the filtration apertures;

FIG. 6B is a enlarged, partially cross-sectional view of the manualadjustment assembly that may be utilized in the adjustment mechanism;

FIG. 7 is a partially cross-sectional side view of the filter assemblydisposed in the filter canister illustrating a further alternativeadjustment mechanism including a motor for automatically modifying thelength L of the filter element to automatically reduce and expand thefiltration apertures;

FIG. 8A is an exploded perspective view of two filter assemblies in anested configuration where one filter assembly is disposedconcentrically about another filter assembly;

FIG. 8B is an enlarged perspective view of a baffle cage included in thenested configuration of FIG. 8A where individual baffles are hollow suchthat a filtration additive can be delivered to the filtration apertures;

FIG. 9 is a schematic view of filter assemblies arranged in parallel andin series and illustrating a controller in communication with the filterassemblies;

FIG. 10A is a schematic view of the fluid flowing through an inside ofthe inner cavity such that a filtrate of the fluid flows through thefiltration apertures and through an outside of the inner cavity, and aretentate of the fluid is retained on the inside of the inner cavity;and

FIG. 10B is a schematic view of the fluid flowing through the outside ofthe inner cavity such that the filtrate of the fluid flows through thefiltration apertures and through the inside of the inner cavity, and theretentate of the fluid is retained on the outside of the inner cavity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the Figures, wherein like numerals indicate like orcorresponding parts throughout the several views, a filter assembly forfiltering a fluid is generally disclosed at 10. It is to be understoodthat the filter assembly 10 and method of filtering according to thesubject invention are capable of filtering both liquids and gases as thefluid. The filter assembly 10 of the subject invention is mostpreferably used to filter fluids having solid particles including, butnot limited to, slurries of biological waste. As such, the filterassembly 10 is commonly used in combination with such devices as shakerscreens, steam scrubbers and/or strippers, biofilters, conveyors, and asa component in mobile filtration units.

As shown best in FIGS. 1A through 2B, the filter assembly 10 includes aplurality of wave coils 12. The plurality of wave coils 12 are formedfrom individual flat wave coils 12. The wave coils 12 include at leastone crest 14 and at least one trough 16 and are arranged axially todefine a filter element 18. Although the wave coils 12 need only includeone crest 14 and one trough 16, the wave coils 12 preferably includemore than one crest 14 and more than one trough 16 and will be describedas such below.

The filter element 18 includes first 20 and second 22 ends and an innercavity 24. The filter element 18 also includes a length L extendingbetween the first and second ends 20, 22. The filter assembly 10 of thesubject invention incorporates at least one retention post 26, as shownin FIG. 4, that extends through the inner cavity 24 and between thefirst and second ends 20, 22 of the filter element 18 to maintain theaxial arrangement of the wave coils 12. The first end 20 of the filterelement 18, as disclosed throughout the Figures, is a bottom end 20 ofthe filter element 18, and the second end 22 of the filter element 18,as disclosed throughout the Figures, is a top end 22 of the filterelement 18. Therefore, the subject description will continue only withreference to the top and bottom ends 20, 22 of the filter element 18.However, the description of the first and second ends 20, 22 of thefilter element 18 is not intended to be limiting, and it is to beunderstood that the first and second ends 20, 22 of the filter element18 could also be a left and right end of the filter element 18. Also,the diameter, the length L, and the stiffness of the filter element 18may vary.

As shown in the Figures, the wave coils 12 that define the filterelement 18 are preferably a wave spring. As such, the wave coils 12preferably extend continuously in an endless path through the crests 14and troughs 16 and between the first and second ends 20, 22 of thefilter element 18. It is to be understood that the wave coils 12 are notrequired to extend continuously. That is, although not preferred, thesubject invention may include connecting members, not shown in theFigures, that connect each of the wave coils 12 together. In thisembodiment, the wave coils 12 can be said to be segmented. Also, in thepreferred embodiment, the wave coils 12 actually extend continuously ina helix through the endless path between the first and second ends 20,22.

Referring now to FIGS. 3A through 3C, the wave coils 12 include ashearing surface 28. The shearing surface 28 imparts shear forces on thefluid as the fluid is being filtered. Preferably, the shearing surfaces28 of the wave coils 12 include a plurality of ridges 30 to enhance theshear forces imparted on the fluid being filtered. As shown in FIGS. 3Athrough 3C, the ridges 30 may be of varying shapes and sizes dependingon the purpose for the filter assembly 10. For instance, if shearing ofthe fluid is the primary purpose, then the ridges 30 having sharp,cone-shaped teeth, as shown in FIG. 3C are ideal. Preferably, the ridges30 are laser-etched both transversely and sequentially along the wavecoils 12, and the ridges 30 are machined to ridge depths on the wavecoils 12 of from hundredths of millimicrons to microns. Alternatively,the ridges 30 may be photo-etched.

It is not required that the wave coils 12 be only flat or ridged forshearing purposes. That is, although not preferred, the wave coils 12may even be formed from round or smooth stock. Furthermore, the wavecoils 12 may include a coating for modifying the flow of the fluid beingfiltered. That is, the wave coils 12 may be coated to adsorb or to repelsolutes in the fluid. Such coatings include, but are not limited to,magnetic coatings, hydrophilic coatings, hydrophobic coatings, andspecific affinity coatings such as antibodies which have a specificaffinity toward a particular antigen such as PCBs. The coatings canassist the wave coils 12 in performing ‘micro-filtration’ when thefiltration apertures are at a 0 micron filtration aperture 34 size,which is described below. The hydrophobic coating is particularly usefulthroughout industrial applications for the filtering of water, oil, andwater/oil mixtures.

The filter assembly 10 also includes a support 32 that engages one ofthe bottom and top ends 20, 22 of the filter element 18 for supportingthe wave coils 12. That is, the support 32 engages either the bottom end20 or top end 22. The support 32 also diverts the fluid inside oroutside of the inner cavity 24 of the filter element 18. In other words,the support 32 also diverts the fluid to one of the inside and outsideof the inner cavity 24. Depending on the embodiment, the support 32functions to divert the fluid inside the inner cavity 24 or to divertthe fluid outside the inner cavity 24. The support 32 will be describedin further detail below.

The crests 14 of one wave coil 12 engage the trough 16 of an adjacentwave coil 12 to define at least one filtration aperture 34, or afiltration pore, between each crest 14 and each trough 16 of theadjacent wave coils 12. Preferably the filtration aperture 34 isspindle-shaped as disclosed throughout the Figures. In a preferredembodiment, the filter element 18 is 2.25 inches in diameter, the lengthL is 5 inches, the filter element 18 includes 100 wave coils 12, andeach wave coil 12 engages the adjacent wave coil 12 three and one-halftimes per 360°. Of course, the number of times each wave coil 12 engagesthe adjacent wave coil 12 can vary. It is to be understood that, withthe exception of FIG. 1A, the crests 14 and troughs 16, as well as theat least one filtration aperture 34 defined therebetween, aresignificantly exaggerated for the descriptive and illustrative purposesof subject invention. As disclosed throughout the Figures, the subjectinvention preferably includes a plurality of filtration apertures 34,and the subject invention will be described below in terms of theplurality of filtration apertures 34 although more than one filtrationaperture 34 is not necessarily required.

The fluid that is diverted by the support 32 is filtered through thefiltration apertures 34. This will be described below. For now, if, forexample, the filtration apertures 34 had a crest 14-to-trough 16separation of 500 microns, then any particulates suspended within thefluid that are less than 500 microns will pass through the filtrationapertures 34 as a filtrate 36 of the fluid, and any particulatessuspended within the fluid that are greater or equal to 500 microns willbe retained on the filter element 18 as a retentate 38, or filter cake,of the fluid.

Referring primarily to FIGS. 4 through 7, the filter assembly 10 of thesubject invention further includes an adjustment mechanism 40. Morespecifically, the adjustment mechanism 40 engages at least one of thebottom and top ends 20, 22 of the filter element 18 for modifying thelength L, extending between the first and second ends 20, 22 of thefilter element 18, to reduce and expand the at least one filtrationaperture 34 or the filtration apertures 34. Therefore, the filtrationapertures 34 are variably-size filtration aperture 34 because they areadjustable or tunable by the adjustment mechanism 40. The filtrationapertures 34 are adjustable, depending on process requirements and thecharacteristics of the filter element 18, specifically of the wave coils12, between a maximum filtration aperture 34 size and a 0 micronfiltration aperture 34 size. The length L is increased to expand the atleast one filtration aperture 34, or to allow the crests 14 and troughs16 to decompress, and the length L is decreased to reduce the at leastone filtration aperture 34, or to compress the crests 14 and troughs 16.Although the adjustment mechanism 40 varies depending on the embodiment,the adjustment mechanism 40 is preferably at least partially disposed inthe inner cavity 24 of the filter element 18.

The adjustment mechanism 40 includes a base plate 42 engaging one of thebottom and top ends 20, 22 of the filter element 18. As shown in FIG. 4,the base plate 42 preferably engages the bottom end 20 of the filterelement 18. The support 32, introduced above, is further defined as thebase plate 42. As such, the base plate 42 supports the wave coils 12 andalso diverts the fluid inside or outside of the inner cavity 24 forfiltering. As understood by those skilled in the art, in the embodimentwhere the fluid is first diverted inside of the inner cavity 24, asshown in FIG. 10A, the base plate 42 is preferably a doughnut-shapedplate surrounding the filter element 18 that blocks the outside of theinner cavity 24 such that the fluid can only flow into the inside of theinner cavity 24.

The base plate 42 includes a base collar 44 and a platform 46 extendingfrom the collar 44. The platform 46 of the base plate 42 is at leastpartially disposed in the inner cavity 24 of the filter element 18. Inthis position, the platform 46 operates to keep the base plate 42 inengagement with either the bottom end 20 or top end 22 of the filterelement 18. The wave coils 12 of the filter element 18 are preferablyanchored to the platform 46. A shoulder portion 48 of the base plate 42is defined between the base collar 44 and the platform 46. The shoulderportion 48 of the base plate 42 actually supports one of the bottom andtop ends 20, 22 of the filter element 18. As shown in FIGS. 4 and 5A,the shoulder portion 48 supports the bottom end 20 of the filter element18.

In the preferred embodiment, the adjustment mechanism 40 furtherincludes a flange member 50 that engages the other of the bottom and topends 20, 22 of the filter element 18 relative to the base plate 42. Theflange member 50, as described in greater detail below, is adjustablyengage relative to the base plate 42 for modifying the length L. As suchthe filtration apertures 34 can be reduced and expanded.

The flange member 50 more specifically includes a flange collar 52 and ayoke 54. The yoke 54 extends from the collar 52 toward the base plate42. Preferably, the yoke 54 is integrally molded with the flange collar52 and includes a yoke base segment 56 that is described below. The yoke54 of the flange member 50 is at least partially disposed in the innercavity 24 of the filter element 18 to keep the flange member 50 inengagement with the other of the bottom and top ends 20, 22 of thefilter element 18 relative to the base plate 42. That is, the yoke 54keeps the flange member 50 in engagement with the top end 22 of thefilter element 18. A shoulder portion 58 of the flange member 50 isdefined between the flange collar 52 and the yoke 54. The shoulderportion 58 of the flange member 50 supports the other of the bottom andtop ends 20, 22 of the filter element 18 relative to the base plate 42.That is, the shoulder portion 58 of the flange member 50 supports thetop end 22 of the filter element 18.

The adjustment mechanism 40 more specifically includes at least onepilot spring 60, preferably a compression spring. As will be describedbelow, the pilot spring 60 subjects the filter assembly 10 to a loadingpressure by biasing the flange member 50. The pilot spring 60 issupported on the yoke 54 of the flange member 50. More specifically, thepilot spring 60 is supported on the base segment 56 of the yoke 54 andis further supported by first and second washers 61, 63. The basesegment 56 of the yoke 54 defines an opening, not numbered, and thepilot spring 60 is supported on the base segment 56 of the yoke 54 aboutthe opening. In this position, the pilot spring 60 biases the flangemember 50 to decrease the length L of the filter element 18 and reducethe filtration apertures 34, and the pilot spring 60 biases the flangemember 50 to increase the length L of the filter element 18 and expandthe filtration apertures 34.

The adjustment mechanism 40 of the filter assembly 10 further includesan adjustment shaft 62. As disclosed throughout the Figures, theadjustment shaft 62 extends from the base plate 42 to engage the flangemember 50 such that the flange member 50 is adjustable relative to thebase plate 42. More specifically, the adjustment shaft 62 extends fromthe base plate 42 through the opening and the pilot spring 60 to engagethe flange member 50 such that the flange member 50 is adjustablerelative to the base plate 42. As such, the length L of the filterelement 18, as described above, can be modified. Preferably, theadjustment shaft 62 extends from the base plate 42 though the innercavity 24 of the filter element 18 to engage the flange member 50. Alsoin the preferred embodiment, the adjustment shaft 62 is threaded and isintegrally molded with the base plate 42. It is to be understood thatthe adjustment shaft 62 may alternatively include locking teeth ordetents, as opposed to threads. In certain embodiments of the subjectinvention, the adjustment shaft 62 can be rendered electromagnetic suchthat the wave coils 12 are magnetically-induced by the adjustment shaft62 to adsorb a fluid having magnetic particles. This electro-magnetizedadjustment shaft 62 is preferably used throughout various medicalapplications including, but not limited to, blood separationapplications where cellular and viral components are removed from bloodusing magnetic antibodies.

To make the flange member 50 adjustable relative to the base plate 42,the subject invention includes an adjustable lock 64 that engages theadjustment shaft 62. More specifically, the adjustable lock 64 isdisposed on the adjustment shaft 62, adjacent the spring 60 and oppositethe base segment 56 of the flange member 50, for adjusting the flangemember 50 relative to the base plate 42 to modify the length L.Manipulation of the adjustable lock 64 directly causes the spring 60 tobias the flange member 50. In the preferred embodiment, the adjustablelock 64 is a threaded adjustment nut 66 that is disposed on the threadedadjustment shaft 62. In alternative embodiments, the adjustable lock 64may be designed to engage and lock locking teeth or detents on theadjustment shaft 62. As shown in FIG. 4, a set screw 68 may extendthrough the adjustable lock 64 to the adjustment shaft 62 to ensure thatthe adjustable lock 64 is locked on the adjustment shaft 62 forretaining the flange member 50 in an adjusted position relative to thebase plate 42.

When operating the adjustable lock 64 to reduce the filtration apertures34, the lock is tightened on the adjustment shaft 62. The pilot spring60 exerts a compressive force on the flange member 50 which, in turn,exerts a compressive force on the filter element 18. As understood bythose skilled in the art, the strength of the pilot spring 60, i.e., theweight required to compress the pilot spring 60, must exceed thestrength of the wave coils 12, i.e., the weight required to compress thewave coils 12, that define the filter element 18. For example, thestrength of the pilot spring 60 could be 32 pounds and the strength ofthe wave coils 12 could be 25 pounds. In such an example, when theadjustable lock 64 is tightened, pressure is applied to the strongerpilot spring 60 which transfers the compressive pressure to the weakerwave coils 12 of the filter element 18 thereby reducing the filtrationapertures 34. The opposite occurs when the adjustable lock 64 isloosened on the adjustment shaft 62. The reduction and expansion of thefiltration apertures 34 may be calibrated by developing a linear plot ofthe rotations of the adjustable lock 64 versus the size of thefiltration apertures 34.

In alternative embodiments of the subject invention, disclosed in FIGS.6A, 6B, and 7, the adjustment mechanism 40 varies. Referring now to FIG.6A, the flange member 50 only includes a flange collar 52, i.e., theyoke 54 is not a functioning component of the flange member 50. Instead,the flange collar 52 acts as a fixed plate, not numbered, engaging theother of the bottom and top ends 20, 22 of the filter element 18relative to the base plate 42. That is, in this embodiment, the fixedplate engages the top end 22 of the filter element 18. In thisembodiment, the flange member 50 also includes a sliding plate 70, alsoknown as a floating plate. As described in the orientation disclosed inFIG. 6A, the sliding plate 70 is disposed between the base plate 42 andthe fixed plate. The base plate 42 is adjustable. More specifically, thesliding plate 70 is supported above the base plate 42 by one or morepilot springs 60. The sliding plate 70 is adjustably engaged relative tothe fixed plate for modifying the length L of the filter element 18 toreduce and expand the filtration apertures 34. Preferably, the slidingplate 70 is adjustable relative to the fixed plate along side posts 71which may, or may not be, the same as the retention posts 26.Preferably, a controller 72, as shown in FIG. 9, is in communicationwith the sliding plate 70 of this alternative adjustment mechanism 40 toautomatically adjust the sliding plate 70 relative to the fixed plate.Other functions of the controller 72 will be described below.

In contrast to automatic adjustment accomplished, in part, with thecontroller 72, a manual adjustment assembly 74, shown generally in FIG.6A and more specifically in FIG. 6B, may be used to modify the length Lof the filter element 18. More specifically, the manual adjustmentassembly 74. The assembly 74 includes an adjustment handle 76. Theadjustment handle 76 rotates a handle adjustment nut 78, preferably apacking nut. The adjustment handle 76, through rotation of the handleadjustment nut 78, contacts a packing spring 80 to advance or pull-backa drive rod 82. As shown in the Figures, the drive rod 82 is in directcontact with the base plate 42 and is in indirect contact with thesliding plate 70 via the pilot springs 60. Of course, it is to beunderstood that a number of turns of the adjustment handle 76 can becorrelated to the size of the filtration apertures 34.

Referring now to FIG. 7, the subject invention includes a motor 84,selectively activated by the controller 72, refer to FIG. 9, toautomatically adjust the adjustment mechanism 40. It is to be understoodthat the motor 84 can be selectively activated by the controller 72 inresponse to various forms of data including, but not limited to, flowdata, pressure data, solids loading data, time data, and particle sizedistribution data. In the alternative embodiment for the adjustmentmechanism 40 disclosed in FIG. 7, the sliding plate 70 is eliminated aswell as the pilot springs 60. Instead, the drive rod 82 of theadjustment mechanism 40 is rigidly fixed, as through a weld or screwend, directly to the base plate 42 that supports the filter element 18.The base plate 42 is adjustable. In this embodiment, referred to as‘direct drive,’ the motor 82 preferably has two settings, a maximumsetting for controlling the size of the filtration apertures 34 duringfiltering, and a minimum setting for expanding the filtration apertures34 during automatic backwashing, which is described below. Of course, ineither of the embodiments disclosed in FIGS. 6A and 7, the manualadjustment assembly 74 and the motor for automatically adjusting theadjustment mechanism 40 can be interchanged.

The filter assembly 10 of the subject invention is utilized incombination with a filter canister 86. The filter canister 86 includesan inlet 88 for receiving the fluid to be filtered and an outlet 90 fordelivering the fluid that has been filtered. As shown in FIG. 5A, theinlet 88 of the filter canister 86 is preferably oval-shaped to impart avortex onto the fluid received into the filter canister 86 forfiltering. The vortex imparted by the oval-shaped inlet 88 is effectivein exposing the fluid to the filter element 18. The vortex alsomaintains the retentate 38 toward an inner wall 92 of the filtercanister 86 and away from the filtration apertures 34 as long aspossible. The canister 86 may also include internal blades, baffles, andthe like to encourage a vortex and more effectively expose the fluid tothe filter element 18.

The filter assembly 10, and in particular the filter element 18 of thefilter assembly 10, is disposed in the filter canister 86. Morespecifically, the filter canister 86 includes a shelf 94 for supportingthe filter assembly 10 in the filter canister 86. A gasket 96, such asan O-ring, is disposed about the flange member 50 to mate with the shelf94 of the filter canister 86. As such, the outlet 90 of the filtercanister 86 is sealed from the inlet 88 of the filter canister 86. Morespecifically, the flange collar 52 of the flange member 50 includes amachined depression 98. The gasket 96 is disposed in the machineddepression 98 to ensure that the filter assembly 10 fits tightly intothe shelf 94 of the filter canister 86. The gasket 96 presses againstthe inner wall 92 of the filter canister 86 such that outlet 90 of thefilter canister 86 is sealed from the inlet 88 of the filter canister86. Furthermore, a plurality of fastening screws 100 extend through theflange collar 52 and into threaded inserts 102 in the shelf 94 of thefilter canister 86. Once the filter element 18 and flange member 50,including the flange collar 52, are inserted into the filter canister86, the fastening screws 100 are tightened to rigidly maintain thefilter assembly 10 on the shelf 94. Rigid maintenance of the filterassembly 10 on the shelf 94 ensures that the outlet 90 and inlet 88 ofthe filter canister 86 are sealed, resists movement of the filterassembly 10 during activation of the adjustment mechanism 40 to modifythe length L, and resists movement of the filter assembly 10 duringautomatic backwashing of the filter assembly 10, which is describedbelow.

Referring now to FIGS. 8A, 8B, and 9, the subject invention preferablyincorporates a plurality of the filter assemblies 10. The plurality offilter assemblies 10 are disclosed in a nested configuration in FIGS. 8Aand 8B. That is, at least one filter assembly 10 included in theplurality of filter assemblies 10 is disposed concentrically aboutanother filter assembly 10 of the plurality. In this nestedconfiguration, a coarse filter assembly 10A is disposed within a finefilter assembly 10B. Of course, it is to be understood that any numberof filter assemblies 10 may be nested with each other.

This embodiment also includes baffle cages 104 that support at least onebaffle 106. The baffle cages 104, supporting the baffles 106, aredisposed within the inner cavity 24 of the filter element 18 of aparticular filter assembly 10. The baffles 106 provide structuralsupport to the filter elements 18 and are preferably angled so as todirect the fluid that is being filtered toward the filtration apertures34. As shown in FIG. 8B, the baffles 106 are preferably hollow such thata filtration additive can be delivered to the filtration apertures 34through the baffles 106. One suitable filtration additive, steam,enhances the filtering, or other stripping, of the fluid that is beingfiltered. Other suitable filtration additives include oxygen forbioprocessing capabilities. Additionally, a plurality of beads 108 maybe disposed within the inner cavities 24 of the filter elements 18 forincreasing a surface area of the fluid that is exposed for filtering.The beads 108 are preferably used in combination with baffles 106 thatare hollow because the beads 108 are particularly effective in exposingthe fluid to be filtered to the filtration additive.

As shown in FIG. 9, the filter assemblies 10 can be arranged in parallelP and/or in series S depending on various process requirements. Theplurality of filter assemblies 10 can also be arranged in a pyramidsequence. The purpose of the pyramid sequence is to utilize more thanone filter assembly 10 having different filtration aperture 34 sizes tosegregate coarse solid particles from intermediate and fine solidparticles where the filtration apertures 34 would otherwise becomeimmediately ‘blinded.’ The pyramid sequence is represented in FIG. 9 bythe filtration aperture 34 sizes of 125 microns, 50 microns, and 25microns. Of course, it is to be understood that such a pyramid sequencemay be continuously altered to accommodate suspended particle sizedistribution and also to equalize flow rates across the filterassemblies 10.

As shown schematically in FIG. 9, the controller 72 is in communicationwith the filter assemblies 10, in particular with the adjustmentmechanisms 40 of each filter assembly 10. The controller 72 is also incommunication with pressure 110, temperature 112, and flow sensors 114,and with the valves, shown schematically, in FIG. 9. The adjustmentmechanism 40 can automatically modify the length L of the filter element18 to automatically reduce and expand the filtration apertures 34 asneeded. The automatic. modification of the length L is primarilyfacilitated by at least one pressure sensor 110 that is in communicationwith the controller 72. The pressure sensor 110 communicates with thecontroller 72, and the controller 72 activates the adjustment mechanism40, preferably through the motor 84, to automatically reduce and expandthe filtration apertures 34.

As shown in FIGS. 5A, 5B, 6A, 7, and 9, an inlet valve 116 is disposedat the inlet 88 of the filter canister 86 and an outlet valve 118 isdisposed at the outlet 90 of the filter canister 86. The outlet valve118 will be described further below. The inlet valve 116 isolates thefilter canister 86 from the fluid to be filtered when necessary such asupon automatic backwashing as described below. The controller 72 is incommunication with the inlet valve 116 to open and close the valve 116and accomplish this isolation. Referring to FIGS. 5A and 5B, the inletvalve 116 is preferably a three-way inlet valve 116. In a filteringposition of the three-way inlet valve 116, as disclosed in FIG. 5A, theinlet valve 116 allows the fluid that is to be filtered to flow throughthe valve 116 and into the inlet 88 of the filter canister 86 forfiltering. However, in a backwash position 120 of the three-way inletvalve, as disclosed in FIG. 5B, the inlet valve 116 isolates the filtercanister 86 from the fluid to be filtered. Instead, as will be describedbelow, the retentate 38 of the fluid is able to flow through the inletvalve 116 when the inlet valve 116 is in the backwash position 120.

Preferably, there is a first pressure sensor 122 disposed at the inlet88 of the filter canister 86 and a second pressure sensor 124 disposedat the outlet 90 of the filter canister 86. The first pressure sensor122 determines an inlet pressure and the second pressure sensor 124determines an outlet pressure. The fist and second pressure sensors 122,124 are in communication with the controller 72. A difference betweenthe inlet pressure and the outlet pressure, which can be determined bythe controller 72, establishes a pressure differential. In reliance onthis pressure differential, the controller 72 can activate the inletvalve 116 to isolate the filter canister 86 from the fluid to befiltered. More specifically, the controller 72 can activate the inletvalve 116 to isolate the filter canister 86 when the outlet pressure isless than the inlet pressure by a predetermined amount.

The method of filtering the fluid according to the subject inventionincludes the step of flowing the fluid toward the support 32 of thefilter assembly 10. In the context of the preferred embodiment, thefluid flows toward the base plate 42 of the adjustment mechanism 40operating as the support 32. The base plate 42 diverts the fluid insideor outside the inner cavity 24 of the filter element 18. Once inside oroutside the inner cavity 24, the diverted fluid is filtered through thefiltration apertures 34 defined between the crests 14 and the troughs16. As such, the filtrate 36 of the fluid passes through one of theinside or outside of the inner cavity 24 and the retentate 38 of thefluid is retained on the other of the inside or outside of the innercavity 24 relative to the filtrate 36. That is, the filtrate 36 passesthrough either the inside or outside of the inner cavity 24 and theretentate 38 is retained on the opposite side of the inner cavity 24 ofthe filter element 18 relative to the filtrate 36.

Referring now to FIG. 10A, if the fluid flows toward the base plate 42and is diverted to the inside of the inner cavity 24 and then throughthe filtration apertures 34, then the filtrate 36 of the fluid, whichalso flows through the filtration apertures 34, passes through theoutside of the inner cavity 24 to the outlet 90 of the filter canister86, and the retentate 38 of the fluid, which cannot flow through thefiltration apertures 34, is retained on the inside of the inner cavity24 of the filter element 18. As described above, in this embodiment, thebase plate 42 is preferably the doughnut-shaped plate surrounding thefilter element 18 that blocks the outside of the inner cavity 24 suchthat the fluid can only flow into the inside of the inner cavity 24.Alternatively, as shown in FIG. 10B, if the fluid flows toward the baseplate 42 and is diverted to the outside of the inner cavity 24 and thenthrough the filtration apertures 34, then the filtrate 36 of the fluidflows through the filtration apertures 34 and passes through the insideof the inner cavity 24 to the outlet 90 of the filter canister 86,whereas the retentate 38 of the fluid is retained on the outside of theinner cavity 24 of the filter element 18.

The method of filtering utilizing the filter assembly 10 according tothe subject invention also includes the step of adjusting the filterassembly 10 to reduce and expand the filtration apertures 34. It is tobe understood that the step of adjusting the filter assembly 10 ispreferably accomplished with the adjustment mechanism 40 incommunication with the pressure sensor or sensors 110, 122, 124 and thecontroller 72 as described above.

The method further includes the step of cleaning the filter assembly 10.The most preferred manner in which to clean the filter assembly 10 is byautomatically backwashing the filter assembly 10 by momentarilyreversing the flow of the filtrate 36, or another fluid, as describedimmediately below. To automatically backwash the filter assembly 10, thefilter assembly 10 is isolated from the fluid to be filtered. To isolatethe filter assembly 10 from the fluid to be filtered, the inlet valve116 at the inlet 88 of the filter canister 86 is closed. In thepreferred embodiment, the inlet valve 116 is activated into the backwashposition 120. Once the filter assembly 10 is isolated from the fluid tobe filtered, the filtrating apertures 34 are expanded. The filtrationapertures 34 may be expanded at regularly-defined time intervals oraccording to other process parameters as described above. However, thefiltration apertures 34 are preferably automatically expanded inresponse to the pressure differential between the bottom and top ends20, 22 of the filter element 18. That is, the filtration apertures 34are preferably automatically expanded when the pressure differentialexceeds the predetermined amount such as when the outlet pressure isless than the inlet pressure by the predetermined amount. Once thefilter assembly 10 is isolated, the adjustment mechanism 40 increasesthe length L of the filter element 18 to expand the filtration apertures34. In the most preferred embodiment, the threaded adjustment nut 66 isautomatically loosened on the threaded adjustment shaft 62 and thelength L of the filter element 18 automatically expands.

Once the filtration apertures 34 are expanded, the flow of the fluidthat has been filtered, i.e., the filtrate 36, is reversed such that thefiltrate 36 flows back through the filtration apertures 34 and theretentate 38 of the fluid is automatically dislodged from the inside orthe outside of the inner cavity 24, depending on the embodiment. It isalso to be understood that the flow of the filtrate 36 may be reversedat the same time, or even before, the filtration apertures 34 areexpanded. Of course, as the retentate 38 is automatically dislodged, thebackwash position 120 of the preferred three-way inlet valve allows thedislodged retentate 38 to flow to a retentate 38 collection reservoirthat collects the backwashed retentate 38. Once the filter assembly 10is clean, the flow of the filtrate 36 returns to normal.

Alternatively, the outlet valve 118 at the outlet 90 of the filtercanister 86 may be a three-way outlet valve 118, similar to thethree-way inlet valve 116. As such, this three way outlet valve 118 canbe manipulated to a position such that a second fluid, distinct from thefluid that has been filtered, i.e., the filtrate 36, can be utilized toflow back through the filtration apertures 34 to automatically backwashthe filter assembly 10 by dislodging the retentate 38. In thissituation, the filtrate 36 is not used to automatically backwash thefilter assembly 10. In this embodiment, the three-way outlet valve 118allows the filter canister 86 to selectively receive fluid forback-washing the filter element 18 when the outlet pressure is less thanthe inlet pressure by the predetermined amount as communicated by thecontroller 72.

The invention has been described in an illustrative manner, and it is tobe understood that the terminology which has been used is intended to bein the nature of words of description rather than of limitation.Obviously, many modifications and variations of the present inventionare possible in light of the above teachings. The invention may bepracticed otherwise than as specifically described within the scope ofthe appended claims. Furthermore, the reference numerals are merely forconvenience and are not to be in any way to be read as limiting.

1-65. (canceled).
 66. A method of filtering a fluid with a filterassembly that includes a plurality of wave coils arranged axially todefine a filter element having first and second ends and an innercavity, and a support engaging one of the first and second ends forsupporting the wave coils, wherein each of the wave coils include atleast one crest and at least one trough with the crest of one wave coilengaging the trough of an adjacent wave coil to define at least onefiltration aperture between each crest and each trough of adjacent wavecoils, said method comprising the steps of: flowing the fluid toward thesupport of the filter assembly; diverting the fluid inside or outsidethe inner cavity of the filter element; and filtering the diverted fluidthrough the at least one filtration aperture defined between each crestand each trough of adjacent wave coils such that a filtrate of the fluidpasses through one of the inside or outside of the inner cavity and aretentate of the fluid is retained on the other of the inside or outsideof the inner cavity relative to the filtrate.
 67. A method as set forthin claim 66 further comprising the step of adjusting the filter assemblyto reduce and expand the at least one filtration aperture.
 68. A methodas set forth in claim 67 further comprising the step of cleaning thefilter assembly.
 69. A method as set forth in claim 68 wherein the stepof cleaning the filter assembly is further defined as automaticallybackwashing the filter assembly.
 70. A method as set forth in claim 69wherein the step of automatically backwashing the filter assemblycomprises the step of isolating the filter assembly from the fluid to befiltered.
 71. A method as set forth in claim 70 wherein the step ofautomatically backwashing the filter assembly further comprises the stepof expanding the at least one filtration aperture.
 72. A method as setforth in claim 71 wherein the step of expanding the at least onefiltration aperture is further defined as expanding the at least onefiltration aperture in response to a pressure differential between thefirst and second ends of the filter element.
 73. A method as set forthin claim 71 wherein the step of automatically backwashing the filterassembly further comprises the step of reversing the flow of thediverted fluid through the at least one filtration aperture such thatthe retentate of the fluid is dislodged from the inside or the outsideof the inner cavity.
 74. A method as set forth in claim 73 wherein thestep of reversing the flow of the diverted fluid through the at leastone filtration aperture is further defined as reversing the flow of thediverted fluid after the at least one filtration aperture has beenexpanded such that the retentate of the fluid is dislodged from theinside or outside of the inner cavity.
 75. A method as set forth inclaim 71 where the step of automatically backwashing the filter assemblyfurther comprises the step of flowing a second fluid through the atleast one filtration aperture such that the retentate of the fluid isdislodged from the inside or the outside of the inner cavity.
 76. Amethod as set forth in claim 67 wherein the filter assembly furtherincludes a base plate engaging one of the first and second ends of thefilter element and a flange member engaging the other of the first andsecond ends relative to the base plate, and the step of adjusting thefilter assembly is further defined as adjusting the flange memberrelative to the base plate for modifying a length L, which extendsbetween the first and second ends of the filter element, to reduce andexpand the at least one filtration aperture.
 77. A method as set forthin claim 76 wherein the step of adjusting the flange member is furtherdefined as biasing the flange member to decrease the length L and reducethe at least one filtration aperture.
 78. A method as set forth in claim76 wherein the step of adjusting the flange member is further defined asbiasing the flange member to increase the length L and expand the atleast one filtration aperture.
 79. A method as set forth in claim 76wherein the flange member includes a flange collar and a yoke extendingfrom the collar toward the base plate thereby defining a shoulderportion of the flange member between the flange collar and the yoke withthe shoulder portion supporting the other of the first and second endsof the filter element relative to the base plate, and the step ofadjusting the flange member is further defined as biasing the yoke todecrease and increase the length L.
 80. A method as set forth in claim67 wherein the step of adjusting the filter assembly is further definedas automatically reducing or expanding the at least one filtrationaperture in response to a differential between an inlet pressure and anoutlet pressure.
 81. A method as set forth in claim 66 wherein the stepof diverting the fluid inside or outside the inner cavity of the filterelement is further defined as diverting the fluid inside the innercavity of the filter element.
 82. A method as set forth in claim 81wherein the step of filtering the diverted fluid through the at leastone filtration aperture is further defined as passing the filtratethrough the outside of the inner cavity and retaining the retentate ofthe fluid on the inside of the inner cavity.
 83. A method as set forthin claim 66 wherein the step of diverting the fluid inside or outsidethe inner cavity of the filter element is further defined as divertingthe fluid outside the inner cavity of the filter element.
 84. A methodas set forth in claim 83 wherein the step of filtering the divertedfluid through the at least one filtration aperture is further defined aspassing the filtrate through the inside of the inner cavity andretaining the retentate of the fluid on the outside of the inner cavity.